Automated storage and retrieval system

Abstract

To provide an automated storage and recovery system.SOLUTION: An automated storage and recovery system comprises: a track system including a first set of a parallel track, arrayed on a horizontal plane and extending in a first direction, and a second set of the parallel track, arrayed on the horizontal plane and extending in a second direction orthogonal to the first direction; a plurality of stacks of storage containers arrayed in a storage column positioned directly under the track system; and a plurality of container handling vehicles for lifting up and moving the storage containers stacked in the stack. The container handling vehicle has an occupied area associated with a horizontal extension part below a horizontal extension part of a grid cell. Further, the container handling vehicle for the automated storage and recovery system and a method for operating the automated storage and recovery system are provided.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to an automated storage and retrieval system. In particular, the present invention relates to an automated storage and retrieval system, which

[0002] is an orbital system, which includes a first set of parallel tracks arranged in a horizontal plane and extending in a first direction, and a second set of parallel tracks arranged in a horizontal plane and extending in a second direction orthogonal to the first direction. The first and second sets of tracks form a grid pattern with a plurality of adjacent grid cells in the horizontal plane, and each grid cell includes a grid opening defined by a pair of adjacent tracks of the first set of tracks and a pair of adjacent tracks of the second set of tracks. An orbital system, a plurality of stacks of storage containers arranged in a storage column located directly below the orbital system, each storage column having a plurality of stacks of storage containers vertically located below the grid opening, a plurality of container handling vehicles for lifting and moving the storage containers stacked in the stacks, the container handling vehicles being configured to move laterally on the orbital system above the storage column and access the storage containers through the grid openings, each of the plurality of container handling vehicles includes a wheel assembly for guiding the container handling vehicle along the orbital system, a container handling vehicle, and is provided with. The container handling vehicle has an occupied area with a horizontal range that is below the horizontal range of the grid cell.

[0003] The present invention also relates to a container handling vehicle for such an automated storage and retrieval system, the container handling vehicle comprising a lower portion having a wheel assembly for guiding the container handling vehicle along a horizontal track system of the automated storage and retrieval system, and a storage space centrally arranged within the lower portion for accommodating storage containers of the automated storage and retrieval system.

[0004] The present invention also relates to a method of operating such an automated storage and retrieval system. [Background technology]

[0005] WO2016 / 120075A1, the contents of which are incorporated herein by reference, shows an example of an automated storage and retrieval system of the type identified above. The disclosed container handling vehicles are dimensioned such that they have a footprint, i.e., a contact area, against the track system, which has a horizontal extension equal to the horizontal extension of a grid cell. This allows container handling vehicles to be operated simultaneously over adjacent grid cells, freeing up more space for the container handling vehicles to travel on the track system compared to prior art systems.

[0006] In the art, such container handling vehicles, i.e., container handling vehicles having a footprint with a horizontal extension corresponding to the horizontal extension of a single grid cell, are sometimes referred to as "single-cell" container handling vehicles.

[0007] Another single-cell container handling vehicle is disclosed in WO2015 / 193278A1, the contents of which are incorporated herein by reference.

[0008] The single cell designs disclosed in WO2016 / 120075A1 and WO2015 / 193278A1 reduce the space required for container handling vehicles to travel on the track system, thus allowing more vehicles to operate on the track system without interfering with each other.

[0009] There are situations where it may be beneficial for a container handling vehicle to have a horizontal extension wider than a single grid cell. For example, if a container handling vehicle is operated under a battery swapping regime where the container handling vehicle is commanded to move to a battery swapping station when it approaches depletion so that its on-board batteries can be swapped, it may be advantageous to locate a battery compartment or slot in a section of the vehicle body that protrudes beyond the vehicle's footprint to facilitate battery swapping.

[0010] If the footprint of a container handling vehicle had a horizontal extension corresponding to the horizontal extension of a grid space, the protruding battery slots would protrude into an adjacent grid cell when the vehicle was positioned above the grid cell, which would prevent other container handling vehicles from operating on the adjacent grid cells and thus limit the space available for other container handling vehicles to operate on the track system.

[0011] In light of the above, it would be desirable to provide an automated storage and retrieval system, a container handling vehicle for such a system, and a method for operating such a system that solves or at least mitigates the aforementioned problems associated with operation of container handling vehicles on a track system. [Prior art documents] [Patent documents]

[0012] [Patent Document 1] International Publication No. 2016 / 120075 [Patent Document 2] International Publication No. 2015 / 193278 Summary of the Invention [Means for solving the problem]

[0013] According to one aspect of the invention, the system includes a grid cell comprising: an overhanging section for each container handling vehicle that extends horizontally beyond the footprint of the container handling vehicle and into an adjacent grid cell when the container handling vehicle is positioned above the grid cell;

[0014] a recessed section arranged to accommodate a protruding section of another container handling vehicle as the another container handling vehicle moves across an adjacent grid cell; The present invention is characterized by comprising:

[0015] The recessed section is an area of clearance adapted to provide clearance for and / or temporarily accommodate a protruding section of another container handling vehicle as it operates across an adjacent grid cell, thus allowing the two container handling vehicles to operate or pass each other over adjacent grid cells without contact being made between the container handling vehicles.

[0016] According to another aspect of the invention, the container handling vehicle is characterized in that it comprises a protruding section extending horizontally beyond the lower portion and a recessed section arranged to receive the protruding section of another container handling vehicle when operating on the track system.

[0017] Another aspect of the invention relates to a method of operating an automated storage and retrieval system, wherein a protruding section of a first container handling vehicle is received within a recessed section of a second container handling vehicle when first and second container handling vehicles operate on adjacent grid cells.

[0018] As a result, when operating on the track system, the recessed section of each container handling vehicle can accommodate the protruding section of other container handling vehicles as they pass across adjacent grid cells, thus enabling the container handling vehicles to travel along adjacent rows of grid cells.

[0019] The recessed section may have a shape complementary to the shape of the protruding section. However, the recessed section may have a different shape from the protruding section as long as it can accommodate the protruding section of another vehicle when passing through adjacent grid cells.

[0020] Advantageously, the recessed section extends across the full width or full length of the container handling vehicle in a direction perpendicular to the direction in which the protruding section extends, thus allowing two vehicles to completely pass each other on adjacent grid cells. In other words, the recessed section forming the clearance area may extend from one side of the container handling vehicle.

[0021] The protruding section and the recessed section may be arranged in the upper part of the container handling vehicle.

[0022] The wheel assembly may include a first set of wheels for engaging a first set of tracks to guide the movement of the container handling vehicle in a first direction and a second set of wheels for engaging a second set of tracks to guide the movement of the container handling vehicle in a second direction.

[0023] The container handling vehicle may include a container receiving storage space for accommodating a storage container and a lifting device arranged to vertically transport the storage container between a storage position in a stack and a transport position in the storage space. The lifting device may include a gripping device configured to releasably grip the storage container and a lifting motor configured to raise and lower the gripping device relative to the storage space.

[0024] The container receiving and storage space may be centrally arranged within the lower part of the container handling vehicle.

[0025] The protruding section may include at least one of a rechargeable battery, a battery slot for storing a replaceable battery, and a sensor for establishing the position of a vehicle on the track system or another opposing vehicle on the track system.

[0026] The wheel assembly may include wheels arranged around the periphery of the storage space.

[0027] In the following, numerous specific details are introduced only as examples in order to provide a thorough understanding of embodiments of the claimed systems, vehicles, and methods. However, those skilled in the art will recognize that these embodiments may be practiced without one or more of these specific details or with other components, systems, etc. In other instances, well-known structures or operations are not shown or described in detail to avoid obscuring aspects of the disclosed embodiments. The present invention provides, for example, the following. (Item 1) An automated storage and retrieval system (1), A track system (10, 16), wherein the track system (10, 16) is arranged in a horizontal plane (P) and includes a first set (11) of parallel tracks extending in a first direction (X) and a second set (12) of parallel tracks arranged in the horizontal plane (P) and extending in a second direction (Y) orthogonal to the first direction (X), and the first and second sets (11, 12) of tracks form a grid pattern (13) having a plurality of adjacent grid cells (14) in the horizontal plane (P), and each grid cell includes a grid opening (15) defined by a pair (11a, 11b) of adjacent tracks of the first set (11) of tracks and a pair (12a, 12b) of adjacent tracks of the second set (12) of tracks, the track system (10, 16); A plurality of stacks (9) of storage containers (8) arranged within a storage column (7) located directly below the track system (10, 16), wherein each storage column (7) has a plurality of stacks (9) of storage containers (8) positioned vertically below the grid opening (15), and A plurality of container handling vehicles (3, 3a, 3b) for lifting and moving the storage containers (8) stacked in the stack (9), wherein the container handling vehicles (3, 3a, 3b) move laterally on the track system (10) above the storage column (7) and are configured to access the storage containers (8) through the grid opening (15), and each of the plurality of container handling vehicles (3, 3a, 3b) A wheel assembly (18) for guiding the container handling vehicles (3, 3a, 3b) along the track system (10, 16) Comprising a container handling vehicle (3, 3a, 3b) and Comprising The container handling vehicles (3, 3a, 3b) have an occupied area (30, 30') with a horizontal extent that is below the horizontal extent of the grid cell (14), Each container handling vehicle (3, 3a, 3b) A protruding section (27), the protruding section (27) extending horizontally beyond the occupied area (30, 30') of the container handling vehicle (3a) and extending into an adjacent grid cell when the container handling vehicle (3a) is positioned above the grid cell (14), and A recessed section (29), the recessed section (29) being arranged to accommodate the protruding section (27) of another container handling vehicle (3, 3a, 3b) when the other container handling vehicle (3, 3a, 3b) operates across adjacent grid cells, and Comprising Characterized by a system (1). (Item 2) The system (1) according to any one of the preceding items, characterized in that the recessed section (29) has a shape complementary to the shape of the protruding section (27). (Item 3) The system (1) according to any one of the preceding items, characterized in that the recessed section (29) extends across the full width or full length of the container handling vehicle (3) in a direction orthogonal to the direction in which the protruding section (27) extends. (Item 4) The system (1) according to any one of the preceding items, characterized in that the protruding section (27) comprises at least one of a rechargeable battery, a battery slot (28) for storing a replaceable battery (25), and a downward sensor. (Item 5) The system (1) according to any one of the preceding items, characterized in that the protruding section (27) and the recessed section (29) are arranged in the upper part of the container handling vehicle (3). (Item 6) The system (1) according to any one of the preceding items, characterized in that the wheel assembly (18) comprises a first set of wheels (19) for engaging with a first set of tracks (11) to guide the movement of the container handling vehicle (3, 3a, 3b) in the first direction (X), and a second set of wheels (20) for engaging with a second set of tracks (12) to guide the movement of the container handling vehicle (3, 3a, 3b) in the second direction (Y). (Item 7) The container handling vehicle (3) comprises a container receiving and storage space (24) for receiving a storage container (8), and a lifting device (21) arranged to vertically transport the storage container (8) between a storage position in the stack (9) and a transport position in the storage space (24), the lifting device (21) comprises a gripping device (22) configured to releasably grip the storage container (8), and a lifting motor (23) configured to raise and lower the gripping device (22) relative to the storage space (24) and a lifting device (21). The system (1) according to any one of the preceding items, characterized by comprising (Item 8) The system (1) according to item 7, characterized in that the container receiving and storage space (24) is arranged centrally within the lower part of the container handling vehicle (3). (Item 9) A container handling vehicle (3, 3a, 3b) for an automated storage and retrieval system (1), the container handling vehicle (3, 3a, 3b) comprising a lower part (17a), the lower part (17a) comprising a wheel assembly (18) for guiding the container handling vehicle (3, 3a, 3b) along the horizontal track system (10, 16) of the automated storage and retrieval system (1), and a storage space (24) arranged centrally within the lower part (17a) for receiving the storage container (8) of the automated storage and retrieval system (1), the container handling vehicle (3a) having a protruding section (27, 27’, 27’’) extending horizontally beyond the lower part (17a), and a recessed section (29, 29’, 29’’) arranged to receive the protruding section (27, 27’, 27’’) of another container handling vehicle (3b) when operating on the track system (10, 16). (Item 10) The container handling vehicle (3, 3a, 3b) according to item 9, characterized in that the protruding section (27, 27’, 27’’) and the recessed section (29, 29’, 29’’) are arranged in the upper part (17b) of the container handling vehicle (3, 3a, 3b) above the lower part (17a). (Item 11) The container handling vehicle (3, 3a, 3b) according to any one of items 9 and 10, characterized in that the recessed section (29, 29’, 29’’) has a shape complementary to the shape of the protruding section (27, 27’, 27’’). (Item 12) The container handling vehicle (3, 3a, 3b) according to any one of items 9-11, characterized in that the protruding sections (27, 27', 27'') and the recessed sections (29, 29', 29'') are arranged on opposite sides of the container handling vehicle (3, 3a, 3b). (Item 13) The container handling vehicle (3, 3a, 3b) according to any one of items 9-12, characterized in that the protruding section (27, 27', 27'') comprises at least one of a rechargeable battery (25), a battery slot (28) for storing a replaceable battery (25), and a sensor for establishing the position of the vehicle on the track system (10, 16) or another vehicle opposite on the track system (10, 16). (Item 14) The container handling vehicle (3, 3a, 3b) according to any one of items 9-13, characterized in that the wheel assembly (18) comprises wheels (19a-19d, 20a-20d) arranged around the periphery of the storage space (24). (Item 15) A method of operating an automated storage and retrieval system (1) according to any one of items 1-8, wherein when the first and second container handling vehicles (3a, 3b) operate on adjacent grid cells, the protruding section (27) of the first container handling vehicle (3a) is received within the recessed section (29) of the second container handling vehicle (3b).

Brief Description of the Drawings

[0028] The following drawings are attached to facilitate understanding of the present invention.

[0029]

Figure 1

[0030]

Figure 2

[0031]

Figure 3

[0032]

Figure 4

Figure 5

Figure 6

Figure 7

[0033]

Figure 8

[0034]

Figure 9

[0035]

Figure 10

[0036]

Figure 11

[0037]

Figure 12

[0038]

Figure 13

Figure 14

Figure 15-1

Figure 15-2

Figure 16

Figure 17

Figure 18

Figure 19

[0039] In the drawings, like reference numerals are used to indicate like parts, elements, or features, unless otherwise explicitly stated or implicitly understood from the context. DETAILED DESCRIPTION OF THE INVENTION

[0040] In the following, embodiments of the present invention will be discussed in more detail, by way of example only and with reference to the accompanying drawings. However, it should be understood that the drawings are not intended to limit the present invention to the subject matter depicted therein.

[0041] Embodiments of the storage structure of the automated storage and retrieval system 1 according to the present invention will now be discussed in more detail with reference to FIGS. 1 - 8.

[0042] The storage structure comprises a framework 2 on which a plurality of container handling vehicles 3a, 3b operate.

[0043] The framework 2 comprises a plurality of upright members 4 and a plurality of horizontal members 5 supported by the upright members 4. The members 4, 5 may typically be made from metal, for example, extruded aluminum profiles.

[0044] The framework 2 defines a three - dimensional storage grid comprising storage columns 7 arranged in rows, and within the storage columns 7, storage containers 8, also known as containers, are stacked to form stacks 9. Each storage container 8 may typically hold a plurality of product items (not shown), and the product items within the storage container 8 may be the same or of different product types depending on the application of the system 1. The framework 2 prevents horizontal movement of the stack 9 of storage containers 8 and guides vertical movement of the containers 8, but typically does not otherwise support the storage containers 8 when stacked.

[0045] The horizontal members 5 comprise a rail or track system 10 arranged in a horizontal plane P above the storage columns 7 (see FIGS. 1 and 3), and on the track system 10, a plurality of container handling vehicles 3 can move laterally above the storage columns 7, raise the storage containers 8 from the storage columns 7, lower the storage containers 8 therein, and transport the storage containers 8 above the storage columns 7.

[0046] The track system 10 comprises a first set 11 of parallel rails or tracks arranged to guide the movement of the container handling vehicle 3 in a first direction X, and a second set 12 of parallel rails or tracks arranged perpendicular to the first set 11 of tracks to guide the movement of the container handling vehicle 3 in a second direction Y perpendicular to the first direction X.

[0047] The track system 10 forms a grid structure or grid pattern 13 in a horizontal plane P (see FIG. 3). The grid pattern 13 comprises a plurality of rectangular, uniform grid locations or grid cells 14 (see FIG. 8), each grid cell 14 comprising a grid opening 15 delimited by a pair 11a, 11b of tracks of the first set 11 of tracks and a pair 12a, 12b of tracks of the second set 12 of tracks. In FIG. 8, the grid cell 14 is indicated by a frame with a dashed boundary, and the grid opening 15 is indicated by a hatched area.

[0048] As a result, the tracks 11a and 11b form a pair of tracks defining a parallel row of grid cells extending in the X direction, and the tracks 12a and 12b form a pair of tracks defining a parallel row of grid cells extending in the Y direction.

[0049] Each grid cell 14 typically has a width W within a spacing between 30 and 150 cm c and a length L within a spacing between 50 and 200 cm. c Each grid opening 15 respectively has a width W c and a length L c less than that of the grid cell 14, typically a width W of between 2 and 10 cm o and a length L o and.

[0050] In the X and Y directions, adjacent grid cells are arranged in contact with each other such that no space exists therebetween.

[0051] An embodiment of the container handling vehicle 3 according to the present invention will now be discussed in more detail with additional reference to FIGS. 10-12.

[0052] Each container handling vehicle 3 includes a vehicle body 17 and a wheel assembly 18 arranged in the lower section or part 17a of the vehicle body 17 (see FIG. 12), enabling lateral movement of the container handling vehicle 3, i.e., movement of the vehicle 3 in the X and Y directions (see FIG. 4).

[0053] The wheel assembly 18 includes a first set 19 of wheels arranged to engage with a pair 11a, 11b of tracks of a first set 11 of tracks, and a second set 20 of wheels arranged to engage with a pair 12a, 12b of tracks of a second set 12 of tracks (see FIG. 10). At least one of the sets 19, 20 of wheels can be lifted and lowered so that the first set 19 of wheels and / or the second set 20 of wheels can be engaged with the individual sets 11, 12 of tracks at any time.

[0054] Each set 19, 20 of wheels includes four wheels 19a, 19b, 19c, 19d; 20a, 20b, 20c, 20d arranged along the side of the vehicle (see FIGS. 4 and 7). Wheels 19a and 19b are arranged in a first vertical plane, and wheels 19c and 19d are parallel to the first vertical plane and arranged in a second vertical plane at a distance from the first vertical plane corresponding to the distance between rails 11a and 11b (see FIG. 8). Wheels 20a and 20b are arranged in a third vertical plane orthogonal to the vertical plane in which wheels 19a-19d are arranged, and wheels 20c and 20d are parallel to the third vertical plane and arranged in a fourth vertical plane at a distance from the third vertical plane corresponding to the distance between rails 12a and 12b.

[0055] At least one of the wheels in each set 19, 20 is electrified in order to propel the vehicle 3 along the track system 10. Advantageously, at least one electric wheel in each set comprises a hub motor, i.e., an electric motor coupled to or incorporated in the hub of the wheel, and directly drives the wheel. An example of a container handling vehicle with such a motor is disclosed in WO2016 / 120075A1, the content of which is incorporated herein by reference.

[0056] Each container handling vehicle 3 comprises a storage compartment or storage space 24 centrally arranged within the lower part 7a of the vehicle body 17 for receiving and holding the storage container 8 when transporting the storage container 8 across the track system 10. The storage space 24 is arranged within the vehicle body 17 and can be accessed from below, i.e., through an opening (not shown) at the bottom of the container handling vehicle 3.

[0057] Each container handling vehicle 3 also comprises a lifting device 21 (see FIG. 10) for the vertical transport of the storage container 8, for example, lifting the storage container 8 from the storage column 7 and bringing it into the storage space 24, and for lowering the storage container 8 from the storage space 24 into the storage column 7. The lifting device 21 comprises a latch or gripping device 22 arranged to engage releasably with the storage container 8. The lifting device also comprises a lifting motor 23 for lowering and raising the gripping device 22 such that the position of the gripping device 22 relative to the vehicle body 17 can be adjusted in a third direction Z orthogonal to the first direction X and the second direction Y (see also FIG. 4).

[0058] Conventionally, and for the purposes of the present application, Z = 1 identifies the uppermost layer of the storage grid, i.e., the layer directly below the orbital system 10, Z = 2 identifies the second layer below the orbital system 10, Z = 3 identifies the third layer, and so on. The container handling vehicle 3 can be considered to travel in layer Z = 0. As a result, each storage column can be identified by its X and Y coordinates, and each storage position within the storage grid can be identified by its X, Y, and Z coordinates.

[0059] The lifting motor 23 is arranged in the second upper part or section 17b of the vehicle body 17 (see FIG. 12), and its upper part 17b is located above the lower part 17a.

[0060] When a storage container 8 stored in the storage grid is accessed, one of the container handling vehicles 3 is instructed to retrieve the target storage container 8 from its position within the storage grid and transport the target storage container 8 to an access station (not shown) where it can be accessed from outside the storage grid or transferred from the storage grid. This operation involves moving the container handling vehicle 3 to the grid cell 14 above the storage column 7 where the target storage container is located, and using the lifting device 21 of the container handling vehicle to retrieve the storage container from the storage column 7. This step involves using the lifting device 21 to lift the storage container from the storage column 7 through the grid opening 15 of the grid cell 14 into the storage space 24 of the vehicle 3.

[0061] When the target storage container is located deep within stack 9, i.e., when one or more other storage containers are positioned above the target storage container, the operation also involves the step of temporarily moving the storage containers positioned above prior to lifting the target storage container from storage column 7. Sometimes, this step, which is sometimes referred to in the art as "digging out," may be carried out using the same container handling vehicle that is subsequently used to transport the target storage container to the access station, or using one or more other cooperating container handling vehicles. Alternatively, or in addition, the automated storage and retrieval system may have a container handling vehicle specialized for the task of temporarily removing storage containers from the storage columns. Once the target storage container has been removed from the storage column, the temporarily removed storage container can be repositioned into the original storage column. However, the removed storage container may alternatively be relocated to another storage column.

[0062] Once the target storage container has been brought into the storage space 24 of the container handling vehicle 3, the vehicle transports the storage container to the access station, where it is unloaded. The access station may typically have grid locations at the periphery of the storage grid, and the storage container can be accessed manually or further transported using a suitable conveyor system.

[0063] When storage container 8 is stored within the storage grid, one of the container handling vehicles 3 picks up the storage container from a pickup station (not shown) that may also serve as the access station and is instructed to transport it to a grid cell above the storage column 7 in which it is to be stored. After any storage container positioned at or above the target position within the storage column stack has been removed, the container handling vehicle 3 positions the storage container at the desired location. The removed storage container may then be lowered back into storage column 7 or may be relocated to another storage column within the storage grid.

[0064] To monitor and control the automated storage and retrieval system so that the desired storage container can be delivered to the desired location at the desired time without the container handling vehicles 3 colliding with each other, the automated storage and retrieval system includes a control system (not shown), which is typically computerized and includes, for example, a database for monitoring and controlling the location of individual storage containers 8 within the storage grid, the contents of each storage container 8, and the movement of the container handling vehicles 3.

[0065] The container handling vehicles 3 typically communicate with the control system via wireless communication means, for example, via a WLAN operating under the IEEE 802.11 (WiFi) standard and / or utilizing mobile telecommunication technologies such as 4G or higher.

[0066] Each container handling vehicle 3 is provided with a battery 25 that powers on-board devices including electric wheels, a lifting motor and on-board control device, and a communication system.

[0067] Each container handling vehicle 3 has an occupied area, i.e., a contact area with respect to the track system 10, having a horizontal extension that is below the horizontal extension of the grid cell 14. In other words, when the vehicle 3 is positioned above the grid cell 14 to lift a storage container from, for example, the storage column 7 or lower a container therein, the occupied area of the vehicle 3 will not extend into adjacent grid cells beyond the grid cell.

[0068] Wheels 19a-19d, 20a-20d are arranged around the periphery of the storage space 24, and the footprint 14 of the vehicle 3 is wider than the storage space 24 just enough to accommodate the wheels 19a-19d, 20a-20d. Thus, the footprint 14 of the vehicle 3 occupies the minimum possible amount of space in the X-Y plane. Since the storage space 24 is positioned between pairs of wheels 19a-19d, 20a-20d on each side of the vehicle 3, the center of gravity of the vehicle 3 will also be located within the footprint 14 when the storage container is raised into the storage space 24.

[0069] Furthermore, the vehicle 3 comprises substantially vertical side walls 26a-26d (see FIGS. 4, 6, and 7) that are coplanar with the vertical plane in which the wheels 19a-19d; 20a-20d are arranged. As a result, the lower part of the container handling vehicle 3 has a substantially cubic shape.

[0070] However, the upper part 17b of the vehicle 3 has a protruding section 27 that extends horizontally in the X direction beyond the otherwise substantially vertical side wall 26c (see, for example, FIGS. 2 and 4). This section 27 houses the battery 25 of the vehicle 3 (see FIG. 7). Positioning the battery in this way is advantageous because it allows for easy access to the battery of a charging or battery exchange station for charging or battery replacement. In particular, when a battery exchange scheme is used and in that case the protruding section 27 comprises a battery compartment or slot 28 (see, for example, FIG. 12), the protruding nature of the section 27 provides an advantageous induction for the battery 25 during the battery exchange operation.

[0071] The protruding section 27 also allows for a larger battery to be installed in the vehicle and can be beneficial when operating the vehicle as a series of vehicles, as disclosed, for example, in International Patent Application No. PCT / EP2016 / 077300.

[0072] Alternatively, or in addition, the protruding section 27 may hold a downward sensor, which may be used to establish the position of the vehicle on the track system 10, e.g., the alignment of the vehicle relative to the grid cell 14, or, e.g., to establish the position of the vehicle relative to other vehicles on the track system 10 when operating the vehicle as a series of vehicles.

[0073] When the vehicle 3 is positioned above the grid cell 14 to access, for example, the container 8 in the storage column 7 that is vertically located below the grid cell 14, the protruding section 27 will extend across adjacent grid cells. In other words, although the vehicle 3 has a contact area with respect to the rail system 10 that does not extend beyond the horizontal extent of one grid cell 14, it has a vertical protrusion that occupies more than one grid cell.

[0074] Normally, this would prevent a second vehicle from traveling across adjacent grid cells, i.e., the grid cells in which the protruding section 27 of the first vehicle extends. This can be a problem as it can reduce the overall capacity of the automated storage and retrieval system.

[0075] However, the container handling vehicle 3 comprises a recessed section 29 arranged in the upper part 17b opposite the protruding section 27. In other words, the protruding section 27 and the recessed section 29 are arranged on opposite sides of the container handling vehicle 3. The recessed section 29 is capable of accommodating the protruding sections 27 of other vehicles when they pass across adjacent grid cells. In particular, the recessed section 29 is complementary in shape to the protruding section 27 and has a shape that extends across the full width of the container handling vehicle 3 in the Y direction, thus enabling the vehicles 3 to pass through each other across adjacent grid cells.

[0076] This is illustrated in FIGS. 4-6, which show that while the second vehicle 3b is positioned across adjacent grid cells, the first vehicle 3a enters so as to operate across a grid cell, and the protruding section 27 of the first vehicle 3a is received within the recessed section 29 of the second vehicle 3b.

[0077] In the disclosed embodiment, the protruding section 27 of each container handling vehicle 3 extends in the X direction, and the recessed section 29 extends across the full width of the vehicle 3 in the Y direction. However, it should be understood that the protruding section may alternatively extend in the Y direction, and the recessed section may extend across the full width of the vehicle in the X direction.

[0078] Each container handling vehicle may alternatively have two protruding sections 27', 27'' extending in two orthogonal directions and two opposing complementary recessed sections 29', 29'', as schematically illustrated by the container handling vehicle shown in FIG. 13. This configuration will also enable the two vehicles to operate across adjacent grid cells without the protruding sections 27' and 27'' interfering with the movement of other vehicles on the track system.

[0079] In the track system 10 shown in FIG. 8, each horizontal member forming the track comprises two tracks. As a result, each horizontal member can accommodate two wheels in parallel. In such a track system, the boundary between adjacent grid cells extends along the center line of the horizontal member, as shown in FIG. 8.

[0080] FIG. 9 shows an alternative rail or track system 16 constituted by extension members each forming a single track, i.e., a track configured to accommodate only one wheel. In such a track system, the boundary between adjacent grid cells extends midway between adjacent extension members forming the single track.

[0081] In FIG. 9, grid cell 14 includes a grid opening 15. To the left (west) of grid cell 14, there is an adjacent grid cell 14W having a grid opening 15W. Similarly, to the right (east) of grid cell 14, there is an adjacent grid cell 14E having a grid opening 15E. Also, below (south) grid cell 14, there is an adjacent grid cell 14S having a grid opening 15S, and above (north) grid cell 14, there is an adjacent grid cell 14N having a grid opening 15N.

[0082] In FIG. 9, the occupied area 30 of the container handling vehicle is schematically illustrated. In this embodiment, the occupied area 30 is defined by the horizontal extensions of the vehicle's wheels. As is apparent from the figure, the occupied area 30 has a horizontal extent that is less than the horizontal extent of the grid cell.

[0083] In FIG. 9, the occupied area 30' of the container handling vehicle according to an alternative embodiment is also schematically illustrated. In this case, the lower portion of the vehicle extends beyond the wheels, and the occupied area 30' has a horizontal extent equal to the horizontal extent of the grid cell.

[0084] As mentioned above, the protruding section 27 may include a battery compartment or slot 28 for the rechargeable or replaceable battery 25. Such embodiments and associated battery exchange schemes will be discussed in more detail below with reference to FIGS. 14 - 19.

[0085] Hereinafter, an example of a charging and / or battery exchange station 40, referred to as a charging station, is shown in FIG. 14 in both a perspective view (FIG. 14A) and a side view along the X direction (FIG. 14B) and a side view along the Y direction (FIG. 14C).

[0086] The charging station 40 is mounted on a charging station substrate 41, which is (directly or indirectly) fixed to the adjacent rails 11a, 11b, 12a, 12b of the track system above the grid columns at or near the outer periphery of the framework structure. The specific grid column containing the charging station 40 will hereinafter be referred to as a charging station cell.

[0087] The illustrated charging station 40 comprises a vertical charging station column 42 that is fixed to the substrate 41 at the lower end 42a. A charging socket 45 is arranged at or near the upper end 42b of the column 42, i.e., opposite the lower end 42a, and is electrically connected to a power supply 44, possibly via a power transformer that converts the charging power to a desired power level.

[0088] The charging socket 45 is further configured to receive a charging plug 46 of a battery 25 disposed on each vehicle 3 (see FIG. 18), thereby enabling the flow of power when the charging plug 46 is electrically coupled to the charging socket 45.

[0089] In a preferred configuration, the charging socket 45 is elastically attached to the charging station 42 such that, for example, the position of the charging socket 45 is fixed in an upper (loading release) position when no external force acts on the charging socket 45 and is fixed in a lower (loading) position when exposed to the weight of the battery 25 to which the charging socket is electrically connected.

[0090] The charging socket 45 and the charging plug 46 may of course be replaced.

[0091] In general, any type of releasable electrical connection between the charging station 40 and the battery 25 is conceivable as a possibility.

[0092] An automated storage and retrieval system as described herein may typically comprise a plurality of such charging stations 40 arranged along the outer periphery of the orbital system. However, one or more charging stations 40 may alternatively or additionally be installed further inside and / or completely outside of the orbital system. In the latter configuration, the charging stations 40 should be connected to the orbital system by additional rails to enable the vehicles 3 to travel to their individual charging stations 40.

[0093] One possible battery exchange process will now be described with particular reference to FIGS. 15-17.

[0094] Vehicle 3, which has transferred its discharged or partially discharged main battery from its battery compartment or slot within battery cover 31 to a first charging station for charging, approaches a second charging station 40 containing a charged or partially charged main battery 25 (see FIGS. 15A and 16C).

[0095] To enable the vehicle to enter the charging station storage cell, a first set 19a-d of wheels should contact the lower orbital system (see FIGS. 15A-D), and a second set 20a-d of wheels closest to the charging station 30 should be high enough above the orbital system so as not to interfere with the orbit along the Y direction.

[0096] When the second set of wheels 20a and 20b enter the charging station storage cell, prior to reaching the horizontal position where the charging station 40 contacts the approaching vehicle 3, the vehicle 3 is lowered towards the rail system. The lowering is carried out as explained above, because the weight of the battery 25 pushes the charging socket 45 down to its lower (loading) position, in order to enable correct alignment with the main battery 25 during the battery exchange process. The lowering of the vehicle 3 also increases the overall stability of the exchange procedure. A typical vertical displacement of the vehicle 3 is 5 - 15 mm, for example 10 mm.

[0097] The charging station 40 should thus be configured such that the height of the main battery 25 during charging with respect to the rail system is approximately equal to the corresponding height of the battery compartment on the vehicle 3 when the vehicle 3 is in the lowered position.

[0098] In order to enable movement of the vehicle 3 without the main battery 25, an auxiliary battery may be arranged in the same or a similar way as disclosed, for example, in patent application No. WO 2015 / 104263 A1, the content of which is incorporated herein by reference. Other solutions, such as the use of an external power source like live rails, manual intervention, etc., may also be envisaged.

[0099] In an alternative embodiment, either the charging station 40 or the vehicle 3 or a combination of both contains a plurality of batteries, thereby avoiding the need for vertical movement between the charging stations during battery exchange. A multi - battery charging station applicable for the storage system 1 mentioned above is disclosed in patent application No. WO 2017 / 220627 A1, the content of which is incorporated herein by reference.

[0100] The available charged battery 25 on the second charging station 40 is mounted on a battery support 43 in the form of two induction pins 43a, 43b that extend laterally into the track system from each side of the upper end 42b of the charging station column 42 in the embodiment shown in FIGS. 14 - 16.

[0101] When the vehicle 3 contacts the charging station 40, a release mechanism 50 (see FIG. 17) is activated, enabling the battery cover 31 to tilt around the axis of rotation.

[0102] The release mechanism 50 includes pivot arms 51 arranged on both sides of the opening of the battery compartment into which the battery 25 is inserted.

[0103] Furthermore, the protruding ends of the induction pins 43a, 43b (constituting the battery support 43) each exhibit a tapered section 52 (see FIGS. 14A and 14C). In response to contact between the pivot arm 51 and the induction pin 43, the pivot arm contact element 51a of each pivot arm 51 is pushed towards the tapered section 52, thereby effecting an upwardly directed pivotal movement of the pivot arm 51 (see FIGS. 15A, 16D, and 17). This pivotal movement releases a security lock 51b (see FIGS. 15 and 19) and enables the aforementioned tilt of the battery cover 31.

[0104] The operation of the release mechanism 50 is illustrated in each of the sequence drawings of FIGS. 15 and 17. For enhanced clarity, enlarged area drawings of the release mechanism 50 are added in FIGS. 15A - C and 15F. The enlarged area drawings clearly show that the activation of the pivot arm movement in response to contact with the tapered section 52 moves the security lock 51b away from the battery cover 27 and the subsequent entry of the battery 25.

[0105] When the induction pins 43 with the attached battery 28 enter a certain distance into the battery compartment 27a (see FIGS. 15B and C), the induction pins 43 release the battery locks 27b, 27c, which allows further entry until the battery 25 is fully in its end position within the battery compartment.

[0106] In FIG. 19, the battery locks 27b, c comprise a battery lock activator 27b in the form of a wheel and one or more blocking teeth 27c extending from the inner wall of the battery cover into the battery compartment. When the tapered ends 52 of the induction pins 43a, b contact the battery lock activator 27b, the battery cover 27 tilts upward, thereby displacing the one or more teeth 27c so that the battery 25 and the induction pins 43a, b can continue their deeper movement into the battery compartment.

[0107] In this end position, before the vehicle 3 reverses, the battery 25 can be electrically connected to both the charging station 40 and, that is, the drive motors for the wheels 19a-d, 20a-d.

[0108] When the battery is in its end position inside the battery compartment and makes electrical contact with the corresponding electrical connector of the vehicle 3, the battery compartment tilts back to its initial position so that the teeth 27c physically lock or hold the battery 25 within the battery compartment. As an example, the teeth 27c may enter dedicated recesses 49a within support rails 49 disposed on both sides of the battery 28 (see FIG. 17).

[0109] The battery locks 27b, c may be any physical obstacle within the battery compartment. As an alternative to the teeth 27c mentioned above, the battery lock may comprise one or more protruding wedges that the battery 25 can pass over in one direction but not in others. In this configuration, the wedge shape would act as the battery lock activator 27b.

[0110] The battery 25 is in its end position and, when properly locked in the battery compartment by the battery locks 27b, c, the second set 20a-d of wheels of the vehicle 3 is lifted from the track system (typically 5 - 15 mm), thereby raising the overall height of the vehicle 3. This operation releases the battery 25 from the battery support 43, for example, from dedicated pockets or tracks within the first and second guide pins 43a, b (see Fig. 14A).

[0111] Here, the battery locks 27b, c lock the battery 25 in the battery compartment and the battery 25 is lifted away from the battery support 43, so that the reverse movement of the vehicle 3 from the charging station storage cell leaves the battery 25 electrically connected to the vehicle 3.

[0112] In addition to enabling normal battery replacement, the interception of the battery 28 into the battery compartment 27a has the advantage that the battery 28 cannot be inadvertently displaced within the battery cover 27 during operation.

[0113] When the control system sends a command to the vehicle 3 to install its battery 28 into the charging station 40 for charging, the steps for transferring the battery 28 from the vehicle 3 to the charging station 40 are essentially equal to, or similar to, the reverse sequence and direction of the steps mentioned above for transferring the battery 28 from the charging station 40 to the vehicle 3.

[0114] Thus, the vehicle 3 is first raised both to allow the vehicle to enter the charging station storage cell without interference of the second set 20 of wheels with the track 11 in the second direction (Y) and to align the operating battery 25 with the charging plug 45 of the charging station 40. As mentioned above, the charging plug 45 is in the exemplary configuration of Figs. 14 - 17 in the upper loading release position.

[0115] During the approach of the vehicle 3 towards the charging station 40, the wedge-shaped ends 52 of the first and second induction pins 43a, b first activate the inclination of the battery compartment via the release mechanism 51, and then activate the battery locks 27b, c, tilting the battery cover upward, thereby removing the blocking teeth 27c from the corresponding recesses 49a in the support rails 49.

[0116] By lowering the vehicle 3 towards the track system, the support rails 49 of the battery 28 engage with the battery supports 43. A subsequent reverse movement of the vehicle 3 will thus leave the battery in the desired charging position on the charging station 40.

[0117] To enable a larger battery within the vehicle 3, both the battery cover and the optional release mechanism 50 may be arranged such that they project horizontally in the X direction beyond the otherwise substantially vertical side walls 26c and 26d. In this way, the overall capacity of each vehicle 3 in the system 1 may be significantly increased without the need to widen the tracks 11, 12.

[0118] For example, if there is a need for manual interference to remove the battery from the battery compartment, e.g., due to general maintenance or accidental battery jamming, a configuration with the protruding release mechanism 50 has an additional advantage in that it enables easy manual unlocking of the battery. That is, the protruding arrangement allows for the application of sufficient manual force to the release mechanism 50, enabling an operation that would be difficult, for example, if the release mechanism 50 were arranged deep within the battery cover 27.

[0119] The protruding configuration described above is also beneficial for ensuring early engagement at the charging station 40.

[0120] An embodiment of the battery 25 is shown in perspective view in FIG. 18. One of the two support rails 49 is shown protruding from the side wall of the battery 25. Also, the same support rail protrudes from the opposing side wall. The purpose of the support rail 49 is both to ensure stable support of the battery 25 on the battery support / guide pin 43 and to ensure accurate guidance of the battery 25 into and out of the battery compartment during replacement. FIG. 19 shows the battery 25 with the support rail 49 fully inserted into the battery compartment. In the particular configuration shown in FIG. 19, the battery 25 is approximately half of the maximum allowable volume of the battery.

[0121] In the foregoing description, various aspects of an automated storage and retrieval system according to the present invention have been described with reference to exemplary embodiments. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the exemplary embodiments and other embodiments of the system that will be apparent to those skilled in the art are considered to be within the scope of the present invention as defined by the following claims.

Claims

A container handling vehicle for an automated storage and retrieval system, wherein the container handling vehicle comprises: a wheel assembly on a lower portion of the container handling vehicle for guiding the container handling vehicle along an orbital system; a protruding section that horizontally extends beyond an occupied area of the container handling vehicle and, when the container handling vehicle is positioned in a grid cell, extends into an adjacent grid cell, the occupied area being a contact area with the orbital system; a recessed section arranged to receive the protruding section of another container handling vehicle when operating across adjacent grid cells; The container handling vehicle comprising the above. The container handling vehicle according to claim 1, wherein the recessed section has a shape complementary to the shape of the protruding section. The container handling vehicle according to claim 1 or 2, wherein the recessed section extends across the entire width or length of the container handling vehicle in a direction orthogonal to the direction in which the protruding section extends. The container handling vehicle according to any one of claims 1 to 3, wherein the protruding section comprises at least one of a rechargeable battery, a battery slot for storing a replaceable battery, or a downward-facing sensor. The container handling vehicle according to any one of claims 1 to 4, wherein the occupied area of the container handling vehicle has a horizontal extension that is below the horizontal extension of the grid cell. The container handling vehicle according to any one of claims 1 to 5, wherein the protruding section and the recessed section are arranged on an upper portion of the container handling vehicle. The container handling vehicle according to any one of claims 1 to 6, wherein the wheel assembly comprises a first set of wheels for engaging a first set of tracks to guide the movement of the container handling vehicle in a first direction and a second set of wheels for engaging a second set of tracks to guide the movement of the container handling vehicle in a second direction. The container handling vehicle further comprises: a storage space for accommodating a storage container; a lifting device arranged to vertically transport the storage container between a storage position in a stack and a transport position in the storage space; The lifting device being: A gripping device configured to releasably grip a storage container, and a lifting motor configured to raise and lower the gripping device relative to the storage space The container handling vehicle according to any one of claims 1 to 7, comprising:

9. The container handling vehicle according to any one of claims 1 to 8, wherein the protruding section and the recessed section are arranged on opposite sides of the container handling vehicle.

10. The container handling vehicle according to any one of claims 1 to 9, further comprising an on-board communication system that enables wireless communication with a control system for monitoring and controlling the movement of the container handling vehicle.

11. The container handling vehicle according to any one of claims 1 to 10, comprising a rechargeable battery configured to be charged at any one of a plurality of charging stations within the automated storage and retrieval system.

Images